1st EHC failure ??

[capewaterman]

Was on my home for lunch yesterday from work when the bike suddenly died just as I was passing someone on a rural 2 lane road. That really sucked as I wasn't exactly in a passing zone and whilst waiting for the damn lady I passed to pass me back so I could get back over b4 the guy coming the other way got to me. Whew !!!!! Anyway bike was dead and wouldn't immed restart while I was still coasting. After pushing it up a slight grade for a hundred yards I finally reached a spot I could get off the road to leave it if I had to. Tried restarting again, no luck. Pulled the seat off to see what I had for lights on the EHC. When key on had 1 red light showing and no start. Shut it off and tried again, this time 2 red lights showing and bike restarted. Tossed the seat back on and made it home for lunch w/ only 10 minutes lost, whew.
Now what to do? I have a wire plus kit on standby I purchased last summer for just this occasion or do I hold off untill I am stranded again? If I need to go ahead with the wireplus is there anybody out there with a pair of the crimpers I need for those Duetch connector pins that would be willing to lend them out for say 3 or 4 weeks? Any help would be greatly appreciated as I am out in the woods here. Not much population around here.

 

[1BADK9]

WHOAAAA Dick, slow down, it may very well be something simple. Give all connectors and wires a thorough inspection to be sure something hasn't rattled loose before jumping the gun on a EHC replacement. Though you have a WP on hand, you may not need it just yet. Good Luck let us know what you find.

 

[Raywood]

Mine did that passing bike on way to Wichita a couple years ago. Pulled over cycled key and she fired back up.
BDM plugged up computer to ignition and said i had a shutdown at time and date. Ignition switch shit off on me.
Make sure you have no key ring on key.
Last year in Oklahoma when EHC finally failed after 7 years i had nothing electrical

Sent from my DROID RAZR using Tapatalk 2

 

[HMAN]

Good to have the WP on hand but like Brooks said...slow down. Do some troubleshooting first. May just be a simple loose connection. As far as crimpers go you dont need the high dollar deutch crimpers. Check around an you can probably find a good pair that will do the job for under $40.

 

[Brew]

The Kline tool is what a lot of us used for crimping and it wont break the bank. You can get it at Lowes, Home DEPOT or Grainger. Get the Non-insulated ones!

Crimping Tool, 10-22AWG, Non-Insulated - Cable and Wire Crimping Tools - Crimping Tools - 5LL35 : Grainger Industrial Supply

 

[Nukeranger]

Yep, I have a WP sitting on the shelf ready for action if needed.

 

[Knuckles]

I didn't want to wait for problems....I know some members have 50k or more miles with the ehc. I went ahead and did the pdm instal last week. Wasn't bad at all and everything works!!!
Selling my ehc for $350, so net cost of the upgrade was $276 and a few hours tinkering with the bike!

 

[SKITZO]

Mine did that passing bike on way to Wichita a couple years ago. Pulled over cycled key and she fired back up.
BDM plugged up computer to ignition and said i had a shutdown at time and date. Ignition switch shit off on me.
Make sure you have no key ring on key.
Last year in Oklahoma when EHC finally failed after 7 years i had nothing electrical

Sent from my DROID RAZR using Tapatalk 2

Raywood, you recomend not having anything on the key, no key chain or ring?
Does having anything on they key cause problems?

Thanks

 

[Raywood]

Your owners manual says same thing. I have a short lanyard with a small skull on it that i tuck in between the head and spark plug wire

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[capewaterman]

Hey Ray, I have no key in the ignition switch at all when running down the road. Apparently my bike came with only 1 key and I think it must be shaved as the very 1st ride I took at 1700 miles when I got home I found no key to shut it off. Luckily I found it 100 yds up the street. So I just use the key to turn on then remove and put in my pocket. I now have 10400 miles on the bike.
I did notice when I started it this morning that the headlight is out but the high beam still works. Perhaps when the headlight blew it created a momentary short back to the EHC causing the shutdown?? I don't know if that might be a possibility. Anyway I now need a headlamp bulb for sure.
Thanx for all the info on the crimpers guys...... I always thought that you had to use the Duetch crimpers in order to get the best quality crimps. I can borrow the klien tool from work. Now I must just decide which path to travel. Any and all input is appreciated.

 

[HMAN]

I experienced a total power failure on my Pit last Sept. Long story short, replaced ECH with WiresPlus an afterwords my electrical system functions perfect. WP takes some time and effort but I believe its worth it. Good luck whichever way you go. We'll be here to help you get that Dog running again.

 

[Scooter28]

Don't put the kit in, I have had nothing but problems since i put my kit in last Septemebr. I am still having problems to date. They are having problem with modules that they obviously can't figure out. If i were you, it is quicker to change the EHC or put in the BigDog version of the PDM kit. My friend put that kit in and hasn't had any problems. I didn't use any special crimpers i use a soldering iron for most of my work.

 

[mml03102]

How long did it take you to install the pdm

 

[Th3InfamousI]

Just an FYI since you have an 04 there was a recall on the main power harness coming loose. Check out my thread took me awhile to track it down but you may have a similiar issue.

Big Dog is recalling certain 2004 Chopper, Bulldog, Ridgeback, Mastiff, Boxer and Pitbull motorcycles. There is a possible loose connection between the harness connector and the electronic harness controller. This condition may cause the motorcycle to experience intermittent loss of electrical power to various components, which can lead to, among other things, a loss of headlamp function or a vehicle stall, increasing the risk of a crash. Big Dog will notify owners and dealers will repair the motorcycles free of charge. The safety recall began on May 24 2010. Owners may contact Big Dog at 316-219-9121. NHTSA campaign ID no. 10v180

http://www.bigdogbiker.com/forums/technical/30808-rookie-wrencher-troubled-dog-lengthy-post-2.html

 

[ksmike]

Make sure your plug wires are tight. Had almost the same exact thing happen to me, and it was a plug wire vibrated off. The EHC on mine wont let it run on one plug.

 

[BigDogBro1]

I did notice when I started it this morning that the headlight is out but the high beam still works. Perhaps when the headlight blew it created a momentary short back to the EHC causing the shutdown?? I don't know if that might be a possibility. Anyway I now need a headlamp bulb for sure.

If the low beam filament burns out the EHC will automatically switch on the high beam.

You need to check the headlight bulb connector and see if the connector has melted and shorted some wires. Replace the plastic bulb connector with a high temp ceramic version found on the web.

 

[bigdogtech01]

Sounds like you might have a bad ignition key switch. You have old style or new? Does it turn on at 5 degrees or 50? The new key switches are 2 position as well. But, $105 retail.

 

[K Shof]

I've got an 02 Husky. The EHC literally fried, melted the whole top of it. Found one on Ebay. Plugged it all in and nothing. Do I have to have it mapped for the bike like a EMC on a Harley? Thanks for anyone's time.

 

[bdmridgeback]

Don't put the kit in, I have had nothing but problems since i put my kit in last Septemebr. I am still having problems to date. They are having problem with modules that they obviously can't figure out. If i were you, it is quicker to change the EHC or put in the BigDog version of the PDM kit. My friend put that kit in and hasn't had any problems. I didn't use any special crimpers i use a soldering iron for most of my work.

The only module issues have only been on module that went out between feb and may. Other than that the only issues have been install related. I, myself have not seen any module falures to speak of aside from out of state people that hsd them installed and connection failure happened.

Dont be affraid to install it, just make sure it is installed correctly and loc tite everything.

 

[capewaterman]

update.... after 3 weeks of looking for loose connections, chaffed wires, etc and finding no problems I finally bit the bullet and did the wireplus install this morning. All went well and now the bike fires right up and stays running. HOORAY!!!!!! Apparently the problem was in the EHC. Seems odd that just the ignition module would go out and nothing else but that is what was happening and is no problem now there is no EHC. Just wanted to post up the final results as may help someone else. It sure sucked not being able to ride for the past 4 weeks.